Thread Breaks

Thread Breaks

If you are experiencing thread breaks, there are a few diagnostic steps we can go through
to narrow down the problem. The first thing you want to do is to determine if the thread is
breaking on all needles, or just one

If you are experiencing thread breaks, there are a few diagnostic steps we can go through
to narrow down the problem. The first thing you want to do is to determine if the thread is
breaking on all needles, or just one

Most Common Causes:  

Incorrect Tension
Damage to the Needle, Rotary Hook, or somewhere else along the thread path.
   
Tools:  Flat Head Screw Driver

Breaking on One Needle:
You want to make the pre-tension and main tension
adjustments are correct. In addition, you also want to check for specific damage
to the needle and anywhere else along the thread path. Follow these steps in order:

1. Pre-Tension Adjustment
2. Main Tension Adjustment
3. Damage to the Needle and the thread path

Breaking on Multiple Needles:
First, you want to ensure the Bobbin tension is
adjusted correctly. If this does not fix the problem, then you will want to check for
damage to the Rotary Hook. Follow these steps in order:

1. Bobbin Adjustment
2. Damage to the Rotary Hook

Pre-tension Adjustment

Embroidery machine pre-tension adjustment

embroidery machine pre-tension adjustment

embroidery machine pre-tension adjustment

Figure 1.

The pre-tension adjustment is located at the top of the embroidery machine.     


Figure 2.

To ensure the pre-tension is adjusted properly, it is recommended that none of
the brass threads are showing

embroidery machine pre-tension adjustment

embroidery machine pre-tension adjustment

Figure 3.     
2. Notice in the diagram the two pre-tension adjustments. #1 has a couple of threads showing, while #2 does not. #2 is adjusted properly. (The pre-tension screw on the right is #1 and the left is #2).

Figure 4.     
3. If the pre-tension screws are showing brass threads, simply turn the outside of the pre-tension screw to right to tighten.
 

Main Adjustment
The Main Tension adjustment is located at the top of the embroidery machine, under the pre-tension adjustment. Please see Figure X above.

1. To ensure the main tension is adjusted properly, it is recommended that 3 to 4 of the brass threads are showing (inside the main tension screw). This tension adjustment can change in order to fine-tune your work. In order to tune it accurately, you should see 1/3 bobbin on the back of your work, and 2/3 should be the color you are sewing. To test, simply set up solid colored letters on each of your needles.

embroidery machine pre-tension adjustment

2. If all of the needles are not producing the desired result, your bobbin adjustment is probably incorrect. Please refer to the bobbin adjustment (insert link to bobbin section) section to correct this.
 

3. If the results are varied, please follow the steps below. If you have one needle that is producing the desired results, you can use this as a gauge to set the other main tension adjustments.

      a. Too much color, not enough bobbin: you will need to tighten the main tension adjustment (turn the main tension adjustment to the right).

      b. Not enough color showing (too much bobbin showing): you will need to loosen the main tension adjustment (turn the main tension adjustment to the left


Bobbin Adjustment

Ensure the bobbin has the proper tension by following these steps:

embroidery machine pre-tension adjustment

embroidery machine pre-tension adjustment

Figure 1.     
1. Holding the bobbin spool in your left hand, pull 2-3 inches of bobbin thread off the spool with your right hand, ensuring the bobbin thread is coming off the spool in a clockwise rotation.

Figure 2.     
2. Place the bobbin spool into the bobbin case; again, ensuring the bobbin thread is coming off the spool in a clockwise rotation. See Figure 2.
 

embroidery machine pre-tension adjustment

embroidery machine pre-tension adjustment

Figure 3.     
3. Place the bobbin case (now with the bobbin spool in it) in your left hand. Pull the excess bobbin thread clockwise around the inside of the bobbin case until you reach the slot in the bobbin case.

Figure 4.     
4. Now, pull the bobbin thread under the tension spring (looks like a flap) and into the tension guide. Make sure the thread pulls smoothly from the bobbin.

embroidery machine drop test

 

Figure 5.

5. Drop Test: To ensure the tension is correct, simply hold on to the excess bobbin thread and motion downwards. The bobbin should come out of the bobbin case and the case should drop about 2 inches and then stop.


Move on to the next step if this occurs, if not, you will need to adjust the bobbin case following these steps:

      a. Did not fall 2 inches: If the bobbin case does not drop appromately 2 inches, then the tension is too tight. Using a flat head screw that was provided to you (labeled “Minus Driver Small”) loosen the adjusting screw one to two minutes to the left.

      b. Fell more than 2 inches: If the bobbin case falls much more than 2 inches, then the tension is too loose. Using a flat head screw that was provided to you (labeled “Minus Driver Small”) tighten the adjusting screw one to two minutes1 to the right. 
 

embroidery machine pre-tension adjustment

6. Trim the thread to 3-4 cm before inserting the bobbin and case into the hook assembly. Long tails can cause the bobbin thread to tangle when the machine begins to stitch.
 
7. Trim the thread to 3-4 cm before inserting the bobbin and case into the hook assembly. Long tails can cause the bobbin thread to tangle when the machine begins to stitch.



embroidery machine damage to rotary hook

Damage to the Rotary Hook

If there is any damage to the Rotary Hook, the thread will break on every needle. You will need to visually examine the hook for any damage.

1. Turn the Rotary Hook so that you can see the top part of the hook. If you have any damage, it will look like the Figure 12.

2. If there is damage to the Rotary Hook, you will need to polish it with crocus cloth (you can find this at any hardware store).

3. First, you will need to remove the rotary hook support bar (black bar just under the needle plate). There will be 2 small flat head screws to remove the bar. This will provide you with more space to polish the hook.

4. Next, polish the damaged area of the rotary hook. You can do this while the Hook is still on the machine. The goal is create a smooth surface, so the thread does not catch on the damaged hook and break.

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